Page 4 - Table Of COnTenTs
T2 ® i Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1Description and Operation . . . . . . . . . . . . . . . . . . . . .2Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . ....
Page 5 - fOrewOrd; This is not a certification, test or study guide for
T2 ® 1 fOrewOrd H e a d q u a r t e r e d i n S u l l i v a n , I l l i n o i s , Hydro-Gear ® is a world leader in the design, manufacture, and service of quality hydrostatic transaxles for the lawn and garden industry . The mission of our company is to be recog- nized by our customers and the indu...
Page 7 - HydraulIC sCHemaTIC
T2 ® 3 figure 1, T2 Hydraulic schematic desCrIpTIOn and OperaTIOn (COnTInued) HydraulIC sCHemaTIC Figure 1 is a schematic of the hydraulic oil circuit . The oil supply for the hydraulic system of the T2 ® is also utilized for lubricating the components of the final drive assembly. The input shaft an...
Page 8 - eXTernal feaTures T2®; — Top View —
4 T2 ® eXTernal feaTures T2® — Top View — — Inboard View — Bypass Arm Oil Fill Plug Control Arm Input Shaft Main Housing Side Housing RH Axle LH Axle RH Axle LH Axle Expansion Tank Input Shaft Expansion Tank Side Housing Main Housing Control Arm Brake Arm
Page 9 - — Outboard View—left —
T2 ® 5 eXTernal feaTures T2® — Outboard View—left — — Outboard View—right — Expansion Tank Bypass Arm Fan Pulley Brake Arm Brake Rotor RH Axle Oil Fill Plug Expansion Tank Control Arm Bypass Arm LH Axle
Page 10 - prOduCT IdenTIfICaTIOn; TECHNICAL SPECIFICATIONS
6 T2 ® Figure 2, Configuration Label prOduCT IdenTIfICaTIOn The model and configuration of the T2 can be determined from the label shown below. TeCHnICal speCIfICaTIOns H Y D R O - G E A R T2-AABC-2X1A-1CXX T2-AABC-2X1A-1CXX 6 352 K1 476 Assembled in USA BOM Model Number Year Built Date (Julian- Day...
Page 11 - warnInG; persOnal safeTy; The floor should be clean and dry, and all ex; serVICInG safeTy; Some cleaning solvents are flammable. Use; safeTy
T2 ® 7 This symbol points out important safety instructions which, if not followed, could en- danger the personal safety and/or property of yourself and others . Read and follow all instruc- tions in this manual before attempting mainte- nance on your transaxle . When you see this symbol - Heed ITs ...
Page 12 - TrOublesHOOTInG; do not attempt any servicing or ad-
8 T2 ® TrOublesHOOTInG In many cases, problems with the T2 ® are not related to a defective transaxle, but are caused by slipping drive belts, partially engaged by- pass valves, and loose or damaged control linkages . Be sure to perform all operational checks and adjustments outlined in Service and ...
Page 13 - serVICe and maInTenanCe; eXTernal maInTenanCe; The fluids used in Hydro-Gear products have; fluId VOlume and leVel; Certain situations may require additional fluid; fluid description
T2 ® 9 serVICe and maInTenanCe nOTe: any servicing dealer attempting a warranty repair must have prior approval before conducting main- tenance of a Hydro-Gear® product unless the servicing dealer is a cur- rent authorized Hydro-Gear service Center. eXTernal maInTenanCe Regular external maintenance ...
Page 14 - eXpansIOn Tank funCTIOn; fluId CHanGe prOCedure
10 T2 ® This transaxle is factory filled, sealed and does not require oil maintenance . However, in the event of oil contamination or degradation, oil addition or change may alleviate certain per- formance problems . 1 . Remove the transaxle from the vehicle . 2. Clean the expansion tank and oil fil...
Page 15 - purGInG prOCedures; Air creates inefficiency because its compres
T2 ® 11 purGInG prOCedures Due to the effects air has on efficiency in hydrostatic drive applications, it is critical that it be purged from the system .These purge procedures should be imple- mented any time a hydrostatic system has been opened to facilitate maintenance or any additional oil has be...
Page 16 - reTurn TO neuTral seTTInG; Confirm the transaxle is in the operating mode
12 T2 ® warnInG pOTenTIal fOr serIOus Injury Certain procedures require the vehicle engine to be operated and the vehicle to be raised off the ground . To prevent possible injury to the ser- vicing technician and/or bystanders, insure the vehicle is properly secured . reTurn TO neuTral seTTInG The r...
Page 17 - brake seTTInG; Insert a 0.020” feeler gage between the; frICTIOn paCk adjusTmenT; Over-tightening will result in difficulty or inability; brake maInTenanCe
T2 ® 13 figure 6, friction pack adjustment brake seTTInG 1 . Remove the brake arm bias spring(134), and then the cotter pin (133) securing the brake castle nut (132) . 2. Insert a 0.020” feeler gage between the brake rotor (121) and top brake puck, and then set the brake by finger tightening or loos...
Page 18 - Tear dOwn and reassembly; HOw TO use THIs manual; The item reference num-; General InsTruCTIOns; from the appropriate kits identified in the Items; TransaXle remOVal; the “Assembly” portions of the procedures. If
14 T2 ® Tear dOwn and reassembly HOw TO use THIs manual Each subassembly illustrated in this section is illustrated by an exploded view showing the parts involved . The item reference num- bers in each illustration are for assembly instructions only . See page 37 for part names and descriptions . A ...
Page 19 - r e Q u I r e d T O O l s; Item description
T2 ® 15 TOOls As a general rule, use the low end of the torque spec on fasteners when reassembling the unit. TOrQues r e Q u I r e d T O O l s miscellaneous sockets Flat Blade Screw Driver (2) 1/2”-3/8” Adapter Torque Wrench 1/2” Deep Air Impact Wrench 7/16” Deep Rubber or Neoprene Mallet 3/4” Deep ...
Page 21 - Refer to Figure 8; As a general rule, use the low end of; nspection; fan and pulley
T2 ® 17 Refer to Figure 8 PULLEY AND FAN CONFIGURATION 1 . Remove the locknut (152), and detach the fan and pulley assembly from the input shaft . 2 . Separate the assembly by removing the screws (153), fan (150) and the pulley (151) . I nspection 1 . Check all components for wear or damage . Replac...
Page 22 - eXpansIOn Tank; Refer to Figure 10; disassembly; . Remove all items previously discussed in; Inspection; . Reassemble all parts in the reverse order
18 T2 ® figure 10, expansion Tank eXpansIOn Tank 145 147 144 143 141 146 Refer to Figure 10 disassembly 1 . Remove all items previously discussed in their recommended order . 2 . Remove the ratchet fastener (147) and discard . 3. Detach the tube (145) from the tank fitting (146). The fitting (146) d...
Page 23 - COnTrOl arm assembly
T2 ® 19 figure 11, Control arm NOTE: Only remove the seal (110) if do- ing a complete disassembly or if the seal is worn or damaged. COnTrOl arm assembly Refer to Figure 11 disassembly 1 . Remove all items previously discussed in their recommended order . 2 . If opening the housing or replacing seal...
Page 24 - reTurn TO neuTral assembly OpTIOn; Refer to Figure 12; sembly. Refer to “Seal Kit” in the Items
20 T2 ® reTurn TO neuTral assembly OpTIOn Refer to Figure 12 disassembly 1 . Remove all items previously discussed in their recommended order . 2 . Remove the spring (167) .3 . Remove the Torx head screw (41) and dis- card . 4 . Remove the scissor arm (164), and the RTN control arm (161) . 5. Remove...
Page 25 - reTurn TO neuTral/rOs assembly OpTIOn
T2 ® 21 reTurn TO neuTral/rOs assembly OpTIOn 3 . Install the control arm (160) .4 . Install the RTN scissor arm (164), washer (163) and Torx head screw (41) . Refer to torque chart on page 15 . 5 . Install the switch retainer over the neutral arm tab . Place the rivet through the switch retainer an...
Page 26 - brake arm & brake assembly
22 T2 ® brake arm & brake assembly Refer to Figure 14 disassembly 1 . Remove all items previously discussed in their recommended order . 2 . Remove the cotter pin (133) and discard . Mark the orientation of the bias spring (134), and long screw (127) . Remove the brake arm spring (134), the cast...
Page 27 - Refer to Figure 15; sIde HOusInG; assembly; eter of the main housing face. See “Sealant
T2 ® 23 Refer to Figure 15 disassembly 1 . Remove all external items previously dis- cussed in their recommended order . 2 . Remove the screws (8), separate side hous- ing (2) from main housing (1) . Inspection 1 . Inspect the bearing and bushing areas in the side cover for wear or damage . Replace ...
Page 28 - rH aXle sHafT; . Remove all items previously discussed, in; . Inspect the axle shaft for wear or damage .; . Assemble items in reverse order of disas-
24 T2 ® rH aXle sHafT Refer to Figure 16 disassembly 1 . Remove all items previously discussed, in their recommended order . 2 . Remove the retaining ring (109) and dis- card . 3 . Remove the lip seal (110) and discard .4 . Remove the outboard bushing (106) .5 . Remove the axle shaft (103) in the di...
Page 29 - Refer to Figure 17; . Remove all external items previously dis-; . Inspect all items of the bull gear set for wear; bull Gear seT
T2 ® 25 Refer to Figure 17 disassembly 1 . Remove all external items previously dis- cussed in their recommended order . 2 . Remove the bull gear set — two miter gears (102) with two differential pins (108), and bull gear (107) . Inspection 1 . Inspect all items of the bull gear set for wear or dama...
Page 30 - reduCTIOn Gear seT; Refer to Figure 18; . Inspect all items of the reduction gear set
26 T2 ® reduCTIOn Gear seT Refer to Figure 18 disassembly Reduction Gear Set: 1 . Remove all external items previously dis- cussed in their recommended order . 2 . Remove the washer (93), jack shaft gear (91) and reduction gear (90) . 3 . Remove the jack shaft (92) and second washer (93) . Inspectio...
Page 31 - InpuT sHafT; Refer to Figure 19; Remove the bearing from pump shaft; Apply a light coating of grease to new
T2 ® 27 InpuT sHafT Refer to Figure 19 disassembly 1 . Remove all external items previously dis- cussed in their recommended order . 2 . Remove the retaining ring (66) and dis- card . 3 . Remove the lip seal (65) and discard .4 . Remove the washer (64) .5 . Remove the pump shaft (61) with pressed on...
Page 32 - swasHplaTe
28 T2 ® swasHplaTe figure 20, swash plate Refer to Figures 20-21 disassembly 1 . Requires removal of all items beginning on page 17 . 2 . Remove the swashplate (40) and pump cylinder block assembly (70) as a single item . NOTE: Removal will be aided by applying a small amount of pressure on the trun...
Page 33 - bypass arm
T2 ® 29 bypass arm Refer to Figure 22 disassembly 1 . Remove all external items previously dis- cussed in their recommended order . 2 . Remove the retaining ring (35) and discard . Remove the bypass arm (34) . 3 . Remove the retaining ring (33) and dis- card . 4 . Remove the bypass rod (32) and the ...
Page 34 - CenTer seCTIOn, mOTOr sHafT & mOTOr blOCk; Refer to Figure 23
30 T2 ® CenTer seCTIOn, mOTOr sHafT & mOTOr blOCk figure 23, Center section, motor shaft & motor block Refer to Figure 23 disassembly 1 . Requires removal of all items beginning on page 17 . 2 . Remove the center section mounting screws (22) . 3 . Remove the center section, the motor shaft (...
Page 35 - fIlTer assembly; CylInder blOCks; The filter can be removed without damaging
T2 ® 31 figure 24, filter assembly fIlTer assembly figure 25, pump/motor Cylinder block assembly CylInder blOCks Refer to Figure 25 Inspect each component of the cylinder block assemblies for wear or damage . Inspect the cylinder blocks’ running surface for scratches . Replace if necessary . NOTE: D...
Page 36 - lH aXle sHafT
32 T2 ® lH aXle sHafT Refer to Figure 26 disassembly 1 . Remove all items previously discussed, in their recommended order . 2 . Remove the retaining ring (109) and dis- card . 3 . Remove the lip seal (110) and discard .4 . Remove the outboard bushing (106) .5 . Remove the axle shaft (104) in the di...
Page 37 - Refer to Figure 27; Inspect the fitting for damage and replace; Install the fitting into the main housing. Refer; eXpansIOn Tank HOse and fITTInG
T2 ® 33 Refer to Figure 27 disassembly 1 . Remove the expansion tank hose (141) .2 . Remove the O-ring (142) from the expan- sion tank fitting (140) and discard. 3. Remove the expansion tank fitting (140). Inspection 1. Inspect the fitting for damage and replace if necessary . assembly 1. Install th...
Page 38 - assembly afTer a COmpleTe Tear dOwn; Prior to applying the new sealant, the
34 T2 ® If the unit has been torn down completely, the following summary identifies the assembly pro - cedures necessary to completely assemble the unit . Each assembly procedure is located by a page reference .The part reference numbers provided in each assembly procedure are keyed to the individua...
Page 39 - sIde HOusInG – sCrew TIGHTenInG seQuenCe
T2 ® 35 figure 29, screw tightening sequence Starting with the number “1” screw location, tighten sequentially through to “10.” Torque each screw to 105 – 155 lb-in (11 .8 – 17 .5 Nm) . NOTE: As a general rule, use the low end of the torque specification. sIde HOusInG – sCrew TIGHTenInG seQuenCe 10 ...
Page 40 - TransaXle eXplOded VIew
Page 41 - TransaXle parTs lIsT
T2 ® 37 T2 ® TransaXle parTs lIsT 1 Housing, Main 2 Housing, Side 7 Seal, Lip (included in Center Section Kit 202) 8 HFHCS 1/4-20 x 1 .25 10 Sealant, Loctite 5900 11 Oil, 20W50 13 Plug 20 Center Section 22 Bolt, Hex Flange 23 Plate, Bypass 24 Check Plug Assembly w/Washer 25 Check Plug/w Assembly w/W...
Page 42 - GlOssary Of Terms
38 T2 ® Axial Piston: Type of design for hydraulic motors and pumps in which the pistons are arranged parallel with the spindle (input or output shaft) . Bypass Valve: A valve whose primary function is to open a path for the fluid to bypass the motor or pump . Also referred to occasionally as the fr...
Page 44 - nOTes
